SupplierPerformanceDevelopmentProcess-PPAP(1)

SupplierPerformanceDevelopmentProcessTask15PPAPTask15:PPAP220-Sep-99TaskDescription•ProductionPartApprovalProcess(PPAP)•Productionpartsaremanufacturedattheproductionsiteusingproductiontooling,gaging,equipment,operators,etc•Partsfromproductionrunareanalyzed•TestresultsandrecordsfromAPQParesubmittedwithPartSubmissionWarrantTask15:PPAP320-Sep-99PurposeForthesuppliertodemonstrate–alldesignrecordsandspecificationrequirementsareproperlyunderstood–theprocesshasthecapabilitytoproduceproductthatmeetsrequirementsTask15:PPAP420-Sep-99SomethingChangedApplicationAIAGPPAPmanualdefineswhenPPAPsubmissionisrequired–Newpart–Correctiontodiscrepancyinprevioussubmission–Designorprocesschange–Changeinsourceofsubcontractedmaterialsorservices–transferorrearrangementoftooling&equipmentTask15:PPAP520-Sep-99Methodology•BuyerentersPPAPsubmissiondateonpurchaseorder•Approverdeterminessubmissionlevel–defaultlevel3–defaultlevel4forrawmaterial•SuppliersubmitsPPAP–PPAPALL.xlselectronicsubmissionrecommended•ApproverevaluatesPPAPpackage–Level5atsuppliersite•Approverdeterminepartsubmissionstatus•NotifysupplierandmanufacturingofstatusTask15:PPAP620-Sep-99•DFMEA•ControlPlan•EarlyProductionContainmentPlan(Pre-LaunchControlPlan)•Processcapabilitystudies•GageMeasurementSystemAnalysis•LabAccreditation&scope•Restricted&ReportableMaterialsform•InterimWorksheet,ifrequiredSupplierDataReceived•Warrant•AppearanceApprovalReport(AAR),asrequired•SampleParts•Print/DesignRecord•EngineeringChangeDocuments•Checkfixtures/aids•ProcessFlowDiagram•PFMEATask15:PPAP720-Sep-99PPAPReviewChecklist•DelphichecklisttoassistwithevaluationofPPAPpackage•ActionplancreatedwithuseofchecklistTask15:PPAP820-Sep-99FlowChart•LinkageofProductCharacteristicsfromDFMEAtoOperationalSteps•OperationnumbersconsistentwithPFMEA,ControlPlan,OperatorInstructions•Ensureidentificationofinspectionandrework•UseA-6ProcessFlowChartchecklistinAPQPmanualtoevaluateTask15:PPAP920-Sep-99PFMEA•LinkagewithDFMEA,ProcessFlow,ControlPlan,OperatorInstructions,etc•DegreetowhichhighRPN’sareaddressedwithpreventivestrategies•ActionPlansassigned,implemented,effectivenessassessedandRPNrecalculated•UseA-7ProcessFMEAchecklistinAPQPmanualTask15:PPAP1020-Sep-99DFMEA•Assessfeasibility,risk,designintentissues•Confirmmanufacturingprocesscapabilityconsidered•FocusonCriticalCharacteristics•LessonsLearnedincorporated•UseA-1DesignFMEAchecklistinAPQPmanualtoevaluateTask15:PPAP1120-Sep-99ControlPlan•EnsureControlPlanisalignedto,andcorrelateswith,DFMEA,ProcessFlow,PFMEA•ControlMethodsappropriatetovariationtype(s)•IncorporatesLessonsLearned,StatisticalData•UseA-8ControlPlanchecklistinAPQPmanualtoevaluateTask15:PPAP1220-Sep-99Pre-LaunchControlPlanEarlyProductionContainmentrequirements–Additionalcontrolsincludedforproperdurationorquantity–PFMEAandstatisticaldatausedtodeterminewhatadditionalcontrolsnecessary•shorttermcapability•longtermcapabilityonsimilarprocessTask15:PPAP1320-Sep-99ProcessCapabilityStudiesCapabilityInterpretationConclusionPpk1.67ProcessprobablymeetscustomerrequirementsCurrentcontrolplansufficient1.33Ppk1.67ProcessmaynotmeetcustomerrequirementsAdditionalcontrolsneededuntilCpk1.33achievedPpk1.33Processwillnotmeetcustomerrequirements100%inpectionisneededuntilCpk1.33achievedTask15:PPAP1420-Sep-99MSAStudies•Measurementuncertaintydetermined–GageR&R,Bias,Stability,andLinearity•GageR&Racceptanceguidelines10%acceptable10-30%maybeacceptable,evaluatetotalvariation30%unacceptable,measuringsystemneedsimprovement•VerifystudyperformedcorrectlyTask15:PPAP1520-Sep-99PartSubmissionStatus•FullProductionApproval•InterimApproval–AuthorizeshipmenttoDelphiwithoutFullProductionApproval–CorrectiveActionPlanisrequired•Rejected–CorrectedsubmissionrequiredbeforeproductionquantitiesmaybeshippedTask15:PPAP1620-Sep-99InterimPartClassApartsfromproductiontoolingandmeetspecs,notallPPAPrequirementshavebeenmetBpartsfromproductiontoolingandrequirereworktomeetspecsCpartsnotfromproductiontooling,partsmeetspecsDpartsdonotmeetspecsEpartsdonotmeetspecsandvehicleswithclassEpartsrequireretrofittomakethemsaleableTask15:PPAP1720-Sep-99Summary•AIAGPPAPmanualdefinesrequirements•APQPProductandProcessValidation•SuppliersubmitsPPAPtoproperlevel•PPAPpackageevaluatedandstatusdetermined•SupplierandDelphimanufacturingsitenotifiedofPPAPapprovalstatusTask15:PPAP1820-Sep-99ReferenceDocuments•AIAGPPAP,SPC,MSA,APQPandControlPlanmanuals•GM1411InterimApprovalWorksheet•AIAGQS-9000Manual•Appendix20:PPAPchecklist•Appendix13:PPAPALL.XLS